Profile for a header of a cooler, a header having such a profile and a cooler having a header

ABSTRACT

A profile for a header of a cooler which also includes numerous parallel tubes. The parallel tubes have a cross-sectional shape between slots for the tubes which further include at least two wave troughs Further, a header is also included having such a profile. A cooler may also be provided, wherein the cooler has such a header.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a United States national phase patentapplication based on PCT/KR2020/095066 filed on Apr. 13, 2020, whichclaims the benefit of German Patent Application No. DE 10 2019 207 905.9filed on May 29, 2019, the entire contents of both of which are herebyincorporated herein by reference.

TECHNICAL FIELD

The invention relates to a profile for a header of a cooler, a headerhaving such a profile and a cooler, in particular for a motor vehicle,having at least one header.

BACKGROUND ART

Coolers for motor vehicles typically comprise numerous parallel tubes,in particular flat tubes, in which a coolant flows. This flow occurs inparticular between two so-called headers which comprise suitable slotsinto which the numerous tubes that are soldered to the header areinserted.

These joints are subject to considerable strain, particularly when thetemperature of the coolant changes quickly. In this case, there areconsiderable temperature differences between individual tubes, such thatthe tubes expand differently, which results in considerable strain onthe joints between the tubes and the header. Damage in these areas istherefore the result of so-called thermal shocks.

DISCLOSURE OF INVENTION

In view of the above, the object of the invention is to provide aprofile, a header and a cooler that are more resistant to thermalshocks.

The object is firstly achieved by the profile as shown and describedherein. According thereto, this has a cross-sectional shape between theslots for the tubes which comprises at least two wave troughs. In theevent of the strain described above, this results in a betterdistribution of the tension, so that resistance to thermal shocks isconsiderably improved. Initial tests show that resistance to thermalshocks is improved by a factor of 2-3.

Although it is sufficient for what is effectively a “double” fixing ofthe tubes by way of two wave troughs for two wave troughs with a crestbetween them to be provided, and for the slots for the tubes to extendbetween the two wave troughs, it is preferred that at least three wavecrests are provided. In other words, this means that each wave trough isfollowed by a further wave crest. It should be noted in this regard thatthe wave troughs extend in the direction of the tubes, and the wavecrests extend in the direction of the interior of the header or thewater tank provided therewith. For the event that three wave crests areprovided, the slots for the tubes extend from the two outer sides atleast to the highest point of the outer wave crests.

Extensive tests have shown that what is important is the configurationof the individual radiuses of the waves. The values set out below applyto widths of the flat tubes of between 14 and 37 mm and/or a materialthickness of the profile according to the invention of between 1 and 2mm, in particular approximately 1.5 mm, and/or a spacing between thetangents to the wave troughs and crests of approximately 4 to 6 mm.Thus, the values according to claims 3 and 4 are preferred for theradiuses, as it has been found that these values result in aparticularly resistant joint between a header having the profileaccording to the invention and the flat tubes. With regard to thedifferent radiuses, it should be noted that these are always measured onthe inner side of the profile, i.e. facing away from the tubes, and anexternal or outer radius designates a radius that is closer to the outerside of the profile if the outer side is understood to be the point atwhich a wave running transversely through the profile begins. It shouldbe mentioned in this respect that the cross-sectional shape of a profileis typically symmetrical with respect to a center in the aforementionedrunning direction of the wave.

It was also shown within the scope of the tests that it is alsoadvantageous for longterm resistance to thermal shocks for at least onewave crest or trough to have at least one flat portion.

Within the scope of extensive tests the formulae according to claim 6were determined for the widths of these flat portions. In this regard itshould be stressed that only one of the values for W1 to W4 must berealized, and that this also applies to at least one of the radiuses R1to R5.

As has been proven, the profile according to the invention can consistof aluminum or an aluminum alloy.

This also applies to the numerous tubes, in particular flat tubes, whichare preferably soldered to at least one profile.

BRIEF DESCRIPTION OF DRAWINGS

In the following, embodiments of the invention that are shown in thedrawings will be described in more detail. In the drawings:

FIG. 1 shows a perspective view of a profile according to the inventionin a first embodiment;

FIG. 2 shows a sectional view of the profile shown in FIG. 1 with adetail enlargement;

FIG. 3 shows a view of a further embodiment of the profile according tothe invention that corresponds to FIG. 2;

FIG. 4 shows a view of a further embodiment of the profile according tothe invention that corresponds to FIG. 2;

FIG. 5 shows a view of a further embodiment of the profile according tothe invention that corresponds to FIG. 2;

FIG. 6 shows a further sectional view of the profile shown in FIG. 2;

FIG. 7 shows a partial sectional view of the profile shown in FIG. 2;and

FIG. 8 shows a partial sectional view of the profile shown in FIG. 4.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As can be seen from FIG. 1, the profile 10 according to the inventionfor a header of a cooler has the form of a shallow dish with anelongated rectangular shape and rounded corners and edges. According toFIG. 1, the profile 10 shown is closed on the upper side by a furtherprofile, such that a header is formed, which is typically verticallyoriented during operation. According to the orientation in FIG. 1,underneath the profile 10 shown and when installed, typically in ahorizontal direction, numerous flat tubes are inserted in slots 16 whichare formed in the “base” of the profile 10. The invention relates to thecross-sectional shape of the base, which effectively remains between theslots 16. The dimensions of the remaining base portions in a directionfrom bottom left to top right according to FIG. 1 are slightly larger,in particular 1.5 to 2.5 times as large as the dimensions of the slots16 in the same direction.

FIG. 2 shows the wave shape of the base, and also the circumferentialweb 18 which surrounds each slot 16 and which essentially has a shapethat corresponds to the flat tube to be inserted therein. As can be seenmore clearly in FIG. 6, the web 18 has a considerable height H whichpreferably remains the same over the circumference and which ensures asecure soldered connection to the flat tubes to be inserted. The slots16 and the webs 18 are typically formed by burring.

FIG. 2 shows the wave shape according to the invention of the profile 10between the slots 16, which in the case shown has two wave troughs 12,which are aligned with the flat tubes that are not shown, and three wavecrests 14. The slots 16 extend approximately to the highest point of thetwo outer wave crests 14.

FIG. 2 shows the profile for flat tubes having a width (measured in FIG.2 from left to right) of 18.5 mm, and FIG. 3 shows a profile for a widthof 14 mm, FIG. 4 for a width of the flat tubes of 25.2 mm and FIG. 5 fora width of the flat tubes of 36.4 mm. As can be seen from FIG. 3, thewaves here are slightly flatter, and in the embodiments according toFIG. 4 the wave crests are slightly drawn apart, as will be explained inmore detail below with reference to FIG. 7 and FIG. 8.

In FIG. 6 the radiuses R1 to R5 are marked out, wherein it should firstof all be stressed that these are always to be measured on the sidefacing away from the flat tubes (that are not shown). An exterior orouter radius is therefore to be understood to be a radius measured onthe (lateral) outer side, in other words in FIG. 6 for the first wavecrest 14.1 to the left. In contrast, an internal or inner radius, suchas R2 in the case of the first wave crest 14.1 and R4 in the case of thefirst wave trough 12.1, is measured at a point further inwards (furtherto the right in FIG. 6). It should also be noted that thecross-sectional shape of the profile according to the invention, whichcan be seen in FIG. 6, is typically symmetrical to the center of thesecond, middle wave crest 14.2, such that the directions described(left/right) can be reversed for the right-hand half of the profileaccording to FIG. 6. The presently preferred values for a header profilefor flat tubes having a width of 18.5 mm are: R1=2.3 mm, R2=2.6 mm,R3=1.9 mm, R4=1.9 mm and R5=4 mm.

The flat portions specified in claim 6 are labelled in FIG. 7 and areshown for the profile in FIG. 6.

The profile in FIG. 8 corresponds to that in FIG. 4, in which there is awider flat portion W3 corresponding to the preferred configuration.

The invention relates to a profile for a header of a cooler, a headerhaving such a profile and a cooler, in particular for a motor vehicle,having at least one header.

1.-10. (canceled)
 11. A profile for a header of a cooler which also comprises a plurality of parallel tubes, having a cross-sectional shape between slots for the tubes which comprises at least two wave troughs.
 12. The profile according to claim 1, further comprising at least three wave crests.
 13. The profile according to claim 11, wherein radiuses in a region of the waves troughs are between 1.5 mm and 50 mm.
 14. The profile according to claim 12, wherein from outside to inside an outer radius (R1) of a first one of the wave crests, an inner radius (R2) of the first one of the wave crests, an outer radius (R3) of a first one of the wave troughs, an inner radius (R4) of the first one of the wave troughs and/or a radius (R5) of a second one of the wave crests measure as follows: R1=1.5 -3.5 mm, R2=2-4 mm, R3=1.9-5 mm, R4=1.9-40 mm, R5=3-50 mm
 15. The profile according to claim 12, wherein at least one of the wave crests or at least one of the wave troughs has at least one flat portion.
 16. The profile according to claim 11, wherein the following applies to at least one flat portion (W1) on a first one of the wave crests from outside to inside, to at least one flat portion (W2) between the first one of the wave crests and a first one of the wave troughs, to at least one flat portion (W3) in the first one of the wave troughs and/or to at least one flat portion (W4) between the first one of the wave troughs and a second one of the wave crests: 5=2.15+R1+W1 2.2=(R2−cos 45*R2)+cos 45*W2+(R3−cos 45*R3) 2.6=(R5−cos α*R5)+cos(90−α)*W4+(R4−cos α*R4) 4.77+T_(width)/2=2.15+R1+W1+cos 45*R2+cos 45*W2+cos 45*R3+W3+sin α*R4+sin(90−α)*W4+sin α*R5 where alpha is an angle between the first one of the wave troughs and the second one of the wave crests with respect to a tangent to the first one of the wave troughs, and T_(width) is the width of a tube.
 17. The profile according to claim 11, wherein the profile consists of aluminum or an aluminum alloy.
 18. A header having at least one profile according to claim
 11. 19. A cooler for an air-conditioning system of a motor vehicle, the cooler having at least one header according to claim
 18. 20. The cooler according to claim 19, wherein the tubes consist of aluminum or an aluminum alloy, and are soldered to the at least one profile.
 21. The profile according to claim 11, wherein radiuses in a region of the waves troughs are between 1.9 mm and 40 mm.
 22. The profile according to claim 11, wherein radiuses in a region of the waves troughs are between 1.9 mm and 5 mm.
 23. The profile according to claim 11, wherein radiuses in a region of the waves troughs are between 2 mm and 4 mm.
 24. The profile according to claim 11, wherein radiuses in a region of the waves troughs are between 1.5 mm and 3 mm. 